Professional Documents
Culture Documents
Benchmarking Shipyards
Benchmarking Shipyards
November 1, 2000
This document contains the proprietary information of First Marine International Ltd
The information is provided under the terms of ATI subcontract 99-00937
Report prepared by
Koichi Baba, MARITECH Engineering, Japan
November 1, 2000
Table of Contents
Introduction
Background and Survey Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Technical Approach and Outputs of the Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Levels of Technology Employed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
The Survey Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 1
Japanese Shipbuilding Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section 2
South Korean Shipbuilding Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Appendix A: Study of the Productivity of Japan and South Koreas Shipbuilding
Yards Based on Statistical Data: by Seiji Nagatsuka of the
Japan Maritime Research Institute (JAMRI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Tables and Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Note: The information contained in this report is believed to be correct but the accuracy
thereof is not guaranteed. MARITECH Engineering, Japan, its employees and
subcontractors cannot accept liability for loss suffered in consequence of reliance on the
information contained herein. This report does not obviate the need to make further
appropriate enquiries and inspections.
Introduction
Background and Survey Methodology
Background
The Manufacturing Technology (MANTECH) Program of the Office of Naval Research funds
programs to improve the manufacturing efficiency of Navy contractors, thereby providing
benefits to both the contractors and the Navy. MANTECH has joined forces with a collaboration
of U.S. shipyards called the National Shipbuilding Research Program (NSRP) to fund the
development of technologies, processes and practices that will lead to more cost effective ship
design and construction. As a means to measure effectiveness of the NSRP collaboration,
MANTECH has undertaken an independent study of the production technology employed by a
sample of the most competitive Asian shipyards to address two objectives:
1.
Identify the U.S. shipbuilding industrys strengths and weaknesses as compared to the
best foreign shipyards as input to the NSRP strategic plan for improvements.
2.
Establish the current levels of technology in U.S. shipyards as a starting point from
which the future effectiveness of the NSRP Program can be measured.
To conduct an objective benchmarking of selected Japanese and South Korean shipyards, the
Office of Naval Research contracted with MARITECH Engineering, Japan (MEJ) using a
benchmarking template developed by First Marine International (FMI). This template was
designed specifically for commercial shipyards and has been used to benchmark over 150
shipyards throughout Europe, Asia and the U.S.
This report presents the findings of the survey of four Japanese and two South Korean shipyards
conducted with the help and assistance of the Shipbuilding Association of Japan (SAJ) and the
South Korean Shipbuilding Association (KSA). The survey team consisted of Koichi Baba as
team leader assisted by Hiroshi Ebarra, Young Won Ma and D. H. Choe. In addition, this
report contains a Study of the Productivity of Japans and South Koreas Shipbuilding Yards
Based on Statistical Data (Appendix A) prepared by Senior analyst Seiji Nagatsuka of the
Japan Maritime Research Institute (JAMRI).
Technical Approach and Outputs of the Study
The survey team visited six of the most competitive Japanese and South Korean shipyards
selected by the SAJ and KSA to make an assessment of the level of technology in fifty generic
operations employed in new commercial ship construction.
The output from the project is:
Two composite reports, one for the four Japanese shipyards and one for the two
South Korean shipyards;
The JAMRI report of the productivity trend of the Japanese and South Korean
shipyards 1975 - 1999;
Workshops to explain the findings of the study to the Navy and the NSRP
Executive Control Board, the Major Initiative Teams, and the Technology Panels
to assist in their preparation of the revised NSRP Strategic Investment Plan.
Reflects shipyard practice of the early 1960s. The shipyard has several berths in
use, low capacity cranes and very little mechanization. Outfitting is largely
carried out on board ship after launch. Operating systems are basic and manual.
In summary, the yard is characterized by the most basic equipment, systems and
technologies and outdated ways of working.
Level 2:
Is the technology employed in the modernized or new shipyards of the late 1960s
and early 1970s. There would be fewer berths in use, possibly a building dock,
larger cranes and a degree of mechanization. Computing would be applied for
some operating systems and for design work. Level 2 is better than basic but is
significantly below world industry norms.
Level 3:
Level 4:
Refers to shipyards that have continued to advance their technology during the
1980s. Generally a single dock, with good environmental protection, short cycle
times, high productivity, extensive early outfitting and integration of steel and
outfit, together with fully developed CAD/CAM and operating systems.
Level 5:
The marking of each element is based on a combination of what the consultants see (e.g., activity
on the shop-floor or examples of planning and engineering outputs) and what they are told. The
scoring system does not necessarily reflect effectiveness or productivity, except that level 5 is
concerned with the effectiveness of the technology in use, as well as the hardware and software
in place.
The Survey Elements
The five levels will be applied to fifty generic commercial shipbuilding operations divided into
seven general areas:
A.
Steelwork
A1.
A2.
A3.
A4.
A5.
A6.
A7.
A8.
A9.
A10.
A11.
B.
Plate stockyard and pretreatment The size and general operation of the plate
stockyard and pretreatment line.
Stiffener stockyard and pretreatment The size and general operation of the
stiffener stockyard and pretreatment line.
Plate cutting The type of plate cutting processes, the general throughput and
flow of material.
Stiffener cutting The type of plate cutting processes, the general throughput and
flow of material.
Plate and stiffener forming The type of plate and stiffener forming processes,
their operation, general throughput and flow of material.
Minor Assemblies The process for assembling minor structural products, their
size, type, the equipment used and the material flow.
Sub-assemblies The process of assembling sub-assembly structural products,
their size, type, the equipment used and the material flow.
Flat unit assemblies The process of assembling sub-assembly structural
products, their size range, the equipment used and the material flow.
Curved and 3D unit assembly The process of assembling curved and 3D
structural units, their general size range, the equipment used and the material
flow.
Superstructure assembly The process of assembling 3D superstructure units,
their general size range, the equipment used and the material flow.
Outfit steel The process of assembling small outfit steel assemblies such as
ladders, WT doors etc., their size range, the equipment used and the material
flow.
Pipe shop The process for manufacturing and assembling pipe of all sizes and
material, the equipment used, and the flow of material.
Machine shop The process for manufacturing and assembling machined parts of
all types, sizes and material, the equipment used, and the flow of material.
Sheet metal working The process for manufacturing and assembling all types of
sheet metal products including vents, furniture, etc., the equipment used, and the
3
B4.
B5.
B6.
C.
Pre-Erection Activities
C1.
C2.
C3.
C4.
C5.
C6.
D.
E.
flow of material.
Electrical The process and equipment used for handling and installing electrical
equipment, cutting and installing cable, connecting and final testing.
General storage and warehousing The process for the delivery, storage, and
issue, the facilities used and the material handling approach.
Storage of large heavy items The process for the delivery, storage and issue of
large heavy items, the facilities used, and the material handling approach.
Ship construction How ship construction is carried out in the shipyard, the
facilities used including cranage.
Erection and fairing How units are assembled on the berth or dock and the
fairing method
Welding How welding onboard ship is accomplished, the method and types
of equipment used.
Onboard services How onboard services are supplied to the ship, the methods
used and the types of equipment available.
Staging and access How staging is applied to the ship and the types of access
arrangement, the methods used and the type of equipment available.
Outfit installation How the final outfitting onboard ship is accomplished
including testing and setting of work.
Painting How painting is organized at all stages of the shipbuilding process
including the type of paint and the equipment used.
Layout and material flow An overview of the shipyard, how its facilities are
laid out and the general flow of material and manufactured products.
4
E2.
F.
General environment As E1. With a general overview of the shipyard and any
environmental factors the shipyard has to comply with.
F2.
F3.
F4.
F5.
F6.
F7.
F8.
F9
Ship design The capability of the shipyard to develop a design from conceptual
design through the development of detailed production information including the
use of computer aided design capabilities.
Steelwork production information What steel production information is
developed for the steelwork assembly process including the use of computer
aided drawing and lofting tools.
Outfit production information What outfit production information is developed
for the outfit assembly process including the use of computer aided drawing tools.
Steelwork coding system What steelwork coding system is used for the
steelwork assembly process including the use of computerized material database
tools.
Parts listing procedure What parts listing system is used in the outfit parts
requisitioning and assembly process including the use of computerized material
database tools.
Production engineering What production engineering activity exists within the
shipyard and its responsibilities including how it relates organizational to the
technical and production departments.
Design for production How design for production techniques are included in the
design process and the development of the build strategy.
Dimensional accuracy and quality control How dimensional accuracy and
quality control techniques are included throughout the ship building process and
at what stages.
Lofting How the lofting function is performed including the use of
computerized tools.
SECTION1
Japanese Shipbuilding Industry
October 26, 1999 to December 03, 1999
Steelwork Production
Plate Stockyard and Treatment
Range: 3.0 - 3.5
Average Score: 3.4
All of the sample shipyards have well laid out and drained stockyards that feature preplanned locations for plates; overhead cranes for magnet handling; and integrated, automated
treatment lines for high-quality primer application. Aside from these sample shipyards, most
Japanese shipyards are equipped with automated treatment lines for primer application, while some
purchase blasted and primed materials from their suppliers. The stockyards do not use automated,
computer controlled cranes for storage and retrieval. Although automation of these processes are
not being given high priority over other plant investments, the shipyards did streamline these
operations by minimizing the number of workers.
Plate Cutting
Range: 4.5 - 4.5
Average Score: 4.5
The Japanese shipyards use Direct Numerical Control (DNC) marking and cutting with
plasma or laser. The information for cutting is transferred from the design database to a server in
production. The cutting machines used involve plasma, laser, and gas. Self-check statistical process
control is fully in place.
Stiffener Cutting
Range: 3.0 - 4.5
Average Score: 4.0
The sample shipyards use integrated Numerical Control (NC) stiffener preparation lines with
some robotics. In most shipyards, the majority of stiffeners are processed using NC stiffener
preparation lines and robots. At one time, one of the sample shipyards employed an NC line, but
abandoned it later because of unsatisfactory performance. Self-check statistical process control is
fully in place.
Minor Assembly
Range: 4.0 - 4.5
Average Score: 4.4
The sample shipyards have well organized workstations and process lanes defined by
assembly family. In most of the shipyards, semi-intelligent robotics are used, though partially.
Specialized jigs, magnetic/hydraulic fairing aids, and good use of semi-automatic welding
equipment are present. Handy type automatic welding equipment is extensively employed.
Sub-Assembly
Range: 3.5 - 4.5
Average Score: 4.0
The sample shipyards use mechanized conveyor lines with workstation sequencing and
integrated automatic positioning, fairing, and welding arrangements. All shipyards partially use
mechanized conveyor lines. Two of the sample shipyards employ semi-intelligent robotics.
Score requirements described herein, with additional use of some robotics. The fitting of outfit
items are integrated with the assembly line process.
Outfit Steel
Average Score: N/A
All of the sample shipyards procure their outfit steel from subcontractors.
(250 mm) nominal diameter and partially utilizes robots for cutting, welding, and handling
processes.
Machine Shop
Range: 3.0 - 3.0
Average Score: 3.0
In all sample shipyards, most of the in-shop machining work is subcontracted. Only
machining related to main engine setting, on-board machining of stern tube, etc. are performed by
the shipyards. The sample shipyards arrange their machinery in a grouped layout for producing a
pre-determined range of products. Palletized storage of work pieces and specialized equipment for
materials handling are used. Although the machines are well maintained and the specialists for this
kind of work are well trained, no NC machines are in the shops. The specialist group is part of the
Engine Room Outfitting Shop.
Electrical
Range: 4.5 - 4.5
Average Score: 4.5
Electrical components are purchased or subcontracted. Those components and cables are
well prepared to be ready for installation and subsequent on-board work. All cables, except lighting
cables, are pre-cut to length before installation. Looms are used extensively for primary and
secondary transit routes, pre-assembled in cableways as appropriate, and installed on-block as much
as possible. Power cables are pulled on-board to avoid any trouble stemming from the connection.
Since lighting cables, as well as other cables, are installed on-block, lighting fixtures are in use
immediately after the hull blocks are erected and welded in position, thus eliminating temporary
lighting for on-board outfitting work.
Pre-Erection Activities
Module Building
Range: 3.5 - 4.0
Average Score: 3.6
The sample shipyards perform module building in purpose-designed and specifically
allocated work areas. Modules are integrated with steel construction and are generally tested prior
to installation. Maximized module assembly in all applicable zones of the ship generally apply
integrated ship production methods. However, all modules are not tested and painted prior to
installation. Hydraulic tests for pipe spools are carried out at the pipe fabrication stage, and the
final hydraulic test for pipe lines is conducted after all the pipes are connected on-board. Final
painting is also carried out on-board after all the tests are completed. One of the sample shipyards makes
a large multi-tier module of the forward part of the engine room. This module is tested and painted prior to
installation.
Pre-Erection Outfitting
Range: 5.0 - 5.0
Average Score: 5.0
In all of the sample shipyards, integrated ship construction is used where assembly and
installation of steel and outfit components are part of the total ship production methodology.
Block Assembly
10
Materials Handling
Range: 4.0 - 4.0
Average Score: 4.0
All of the sample shipyards have an extensive palletized system for steel and outfit materials,
components, and subassemblies. Self-loading transport systems are used with stools and trestles for
movement of large steel, outfit components, and assemblies. Well-defined storage areas are located
throughout the shipyard. Coordinated handling activities exist, and various handling and
manipulating equipment has been devised and employed in all areas.
The sample shipyards carry out all erection in large natural blocks, with no surplus material
on the edges of blocks. Alignment is performed with optical equipment including lasers. Nonwelded fairing aids and purpose-designed automatic fairing equipment are not extensively utilized.
However, the accuracy of the blocks is so well controlled that not many man-hours are spent on
block fitting work.
Welding
Range: 4.5 - 4.5
Average Score: 4.5
In the sample shipyards, downhand butt welds (even those that are relatively short) are made
by lightweight or heavy automatic tractors. Semi-automatic equipment for downhand and positional
welding, and one-sided welding procedures are used extensively. Vertical butt welds are made by
an automatic climbing process. Furthermore, welding robots are partially employed in all of the
sample shipyards.
Onboard Services
Range: 4.0 - 5.0
Average Score: 4.6
Routing of all services is pre-planned in the sample shipyards. Services systems are
designed in modular form to facilitate expansion or withdrawal of each system without interrupting
the remainder of the supply. All temporary cables and hoses are held clear of the decks, and services
systems are very well planned. The required level of on-board services is reduced due to the large
blocks and early outfitting. Pipe services required for construction work are not left in place after
vessel completion (they do not believe this is ideal), but other things (such as lifting eyes) are left
if they are useful to the customer. The ships lighting systems are used instead of temporary
lighting.
Outfit Installation
Range: 3.5 - 4.0
Average Score: 3.9
12
The sample shipyards ship lift less than 5% of the pipes, cables are cut prior to fitting on
board, and most systems at two of the sample shipyards are tested within 10 days after launch.
However, at all of the other sample shipyards, most systems are tested within 15 to 20 days after
launch. As an example of the percentage of ship-lifted pipes, one of the shipyards reports that only
3% to 4% of engine room pipes is ship-lifted.
Painting
Range: 4.0 - 4.5
Average Score: 4.1
Purpose-designed cells or a process line for steel block preparation and painting to final coat
is used in the sample shipyards. Only joint completion remains to be done after erection. Robots
are not yet used for painting, although they are being developed in some of the shipyards.
General Environment
Range: 4.0 - 4.5
Average Score: 4.3
The sample shipyards production facilities are mainly purpose-designed with good working
environments and low noise levels. Permanent fume extraction is integral to the workstations, and
good housekeeping exists in all areas. Climate control is not yet achieved, but the work environment
in the summer has been improved with cooled air supply systems. Some waste management
measures have been taken to prevent pollution.
Production Engineering
14
Lofting Methods
Range: 4.5 - 5.0
Average Score: 4.9
In most of the sample shipyards, all design and production information is contained within
15
a single 3-D product model with no separate lofting function. However, in one of the sample
shipyards, some of the information is generated separately from the product model during
production.
Master Planning
Range: 5.0 - 5.0
Average Score: 5.0
In all sample shipyards, variations in strategy can be assessed by an integrated computer
system which allows interaction between the strategic, tactical, and detailed levels of project
planning and the assessment of resource and workstation utilization. In all sample shipyards, master
planning takes into consideration all the essential factors such as build strategy and efficient
utilization of manpower, workstations, etc.
Steelwork Scheduling
Range: 4.0 - 5.0
Average Score: 4.4
In most of the sample shipyards, detailed workstation loading is done on the basis of work
analysis by using either manual or computer methods. In one of the sample shipyards, integrated
computer systems generate and balance workstation schedules directly from a single 3-D product
model. Schedules are not directly generated from the single 3-D model in the other shipyards.
Outfit Scheduling
Range: 4.0 - 4.5
Average Score: 4.3
In most of the sample shipyards, detailed workstation loading is done on the basis of work
analysis by using either manual or computer methods. Production schedules are coordinated to a
common demand schedule. In one of the sample shipyards, schedules for piping only are directly
generated from the 3-D model. In other shipyards, schedules are made independently from the 3-D
model.
16
Production Control
Range: 4.0 - 5.0
Average Score: 4.5
In most of the sample shipyards, scheduling and control systems are fully integrated and the
foremen are provided with all the required information. Effective data retrieval from the shop floor
is consolidated into a computer-based management information system. In one of the sample
shipyards, on-line performance feedback is provided by direct shop-floor data extraction and input
into integrated computer systems that are linked to financial and commercial systems. In other
shipyards, the computer system is not linked to financial and commercial systems.
Stores Control
Range: 4.0 - 5.0
Average Score: 4.4
In three of the sample shipyards, all material and locations are fully coded. Stock levels,
material availability, and location are available on a computer system. Movement is directly
recorded into the computer by assigned personnel. The material system is integrated with
production control and costing systems. In one of the sample shipyards, stores control is integrated
with a single 3-D product model and the production scheduling and control systems.
Quality Assurance
Range: 4.0 - 4.5
Average Score: 4.4
In all sample shipyards, an accredited and functioning QA system exists. The workforce is
trained and aware of quality issues. There is full traceability of all ship components and documents,
low occurrence of re-work, and full analysis and correction of problems. All sample shipyards have
acquired ISO-9000. The workforce is well trained to focus on quality, and a zero defect policy
exists.
18
Shipyard A
1962
0.44mil.
1,000
10,000
6-7
420,000
7. Facilities
[Shipyard A]
Shipyard B
1971
0.55mil.
900
10,000
10-12
500,000
Shipyard C
1889
0.37mil.
1,100
19,000
5-6
776,000
(In 1999)
Shipyard D
1972
1.5mil.
1,500
15,000
36653
600,000
(Average of
latest 5 years)
[Shipyard B]
Building Docks
No. 2
No. 3
Building Dock
Length
Width
Depth
400M
72M
12.5M
200M
72M
12.5M
Length
Width
Depth
560M
80M
12.6M
Cranes
300T Goliath
Crane
300T LLC
Cranes
500000
40000
500000
[Shipyard C]
[Shipyard D]
Building Docks
No. 2
No. 3
Building Dock
Length
Width
Depth
345M
65M
11.2M
510M
80M
13.5M
Length
Width
Depth
990M
100M
14.5 - 9.55M
Cranes
2 x 200T LLC
3 x 300T LLC
Cranes
200000
800000
1000000
19
Table of Acronyms
Acronym
Definition
3-D
Three-Dimensional
DNC
JIT
Just-In-Time
NC
Numerical Control
QA
Quality Assurance
R&D
TIG
20
SECTION2
South Korean Shipbuilding Industry
November 15 19, 1999
Steelwork Production
Plate Stockyard and Treatment
Range: 3.5 - 4.0
Average Score: 3.75
The sample stockyards are well laid out and drained with pre-planned locations for plates;
overhead cranes for magnet handling; and an integrated, automated treatment line with high quality
primer application. Material input and withdrawal are almost fully computer controlled, depending
on the shipyard. Some of the workers are deployed in the stockyard; however, very few workers
are in the most advanced shipyard.
Plate Cutting
Range: 4.5 - 4.5
Average Score: 4.5
In the sample shipyards, plate cutting is accomplished by predominantly using numerical
control, with some Computer Numerical Control (CNC), marking and cutting with plasma.
Additionally, a Direct Numerical Control (DNC) marking/cutting system is partially used. Selfcheck statistical process control is fully in place.
Stiffener Cutting
21
Minor Assembly
Range: 3.5 - 4.0
Average Score: 3.75
Some of the shipyards have a clearly defined minor assembly stage with dedicated work
areas. Some general jigs, reusable fairing aids, and an extensive use of semi-automatic welding
equipment are present. Well-organized workstations and process lanes, defined by assembly family,
exist. Specialized jigs are used 100% in one of the shipyards, but only used 50% in the other
shipyard.
Sub-Assembly
Range: 3.5 - 4.5
Average Score: 4.0
Both of the sample shipyards use mechanized conveyor lines with workstation sequencing.
One of the shipyards applies automatic positioning, whereas the other shipyard does not.
in both shipyards. One-sided automatic welding is used for all plate joining in flat unit assembly.
Outfit Steel
Average Score: N/A
All the sample shipyards procure their outfit steel from subcontractors.
Machine Shop
Average Score: N/A
Both sample shipyards procure their machining work from subcontractors.
Electrical
Range: 4.0 - 4.0
Average Score: 4.0
The sample shipyards have well-equipped manufacturing facilities which are used to produce
a rationalized range of electrical components. All cables are pre-cut to length before installation,
and the electrical work is performed by the shipyards employees and subcontractors. Both
shipyards share the work content with subcontractors as follows:
Shipyard cable pre-cutting, cable connection, and testing
Subcontractors cable way installation and cable pulling
Pre-Erection Activities
Module Building
Range: 3.5 - 3.5
24
Pre-Erection Outfitting
Range: 4.5 - 4.5
Average Score: 4.5
In the sample shipyards, a pre-determined high level of advanced outfitting of steel prior to
erection is achieved on first of class. Both shipyards are making every possible effort to integrate
the pre-erection of steel and outfitting, but have not yet achieved perfect integration. This would
include integrated ship construction where the assembly and installation of steel and outfit
components are part of a total ship production methodology.
Block Assembly
Range: 4.0 - 4.5
Average Score: 4.25
The sample shipyards block assembly is located in purpose-designed workshops with
natural block breakdown throughout the ship. Extensive one-sided welding techniques with
application of semi-automatic and automatic welding processes are utilized. High levels of preerection outfitting exist as well as use of purpose-designed access equipment. Unit and block
dimensions are accurate, and the facilities in one of the shipyards slightly exceeds this description.
building docks close to the point of erection. Specialized transport and handling equipment are used
for delivering blocks to the construction area. Only a minimum block storage area is required
because of the minimal difference between planned and actual progress of construction.
Materials Handling
Range: 4.0 - 4.0
Average Score: 4.0
The sample shipyards use an extensive palletized system for steel and outfit materials,
components, and sub-assemblies. Self-loading transport systems are used with stools and trestles
for moving large steel and outfit components and assemblies. Well-defined storage areas are present
throughout the shipyard with coordinated handling activities. Furthermore, conveyors and special
purpose handling and manipulating equipment are used where necessary.
Welding
Range: 4.0 - 4.5
Average Score: 4.25
In the sample shipyards, downhand butt welds (even those that are relatively short) are made
by lightweight or heavy automatic tractors. There is extensive use of semi-automatic equipment for
26
downhand and positional welding, and one-sided welding procedures are used extensively. Vertical
butt welds are made by an automatic climbing process. In one of the shipyards, welding robots are
partially employed.
Onboard Services
Range: 4.5 - 4.5
Average Score: 4.5
The sample shipyards pre-plan the routing of all services. Services systems are designed in
modular form to facilitate expansion or withdrawal of each system without interruption to the
remainder of the supply. All temporary cables and hoses are held clear of decks. Services systems
are very well planned. The required level of on-board services is reduced due to the large blocks
and early outfitting. Pipe services required for construction work are not left in place after vessel
completion; however, other items (such as lifting eyes) are left if they are useful to the customer.
The ships lighting systems are used instead of temporary lighting.
Outfit Installation
Range: 4.0 - 4.0
Average Score: 4.0
In the sample shipyards, less than 5% of the pipes is ship lifted; in one of the shipyards, only
2% to 3% of the pipes is ship-lifted. Cables are cut prior to fitting on board, and most systems are
tested within fifteen days of launch. There is extensive module building and block outfit.
Painting
Range: 4.0 - 4.5
Average Score: 4.25
Purpose-designed cells, or a process line for steel block preparation and painting to final
coat, is used in the sample shipyards. Completion of the erection joints remains to be done after
erection. The level of one of the shipyards is considered to slightly exceed the requirements for this
score. Robotics are not yet used in the paint cells.
General Environment
Range: 4.0 - 4.0
Average Score: 4.0
The sample shipyards mainly employ purpose-designed production facilities with good
working environments and low noise levels. Permanent fume extraction is critical to workstations,
and good housekeeping exists in all areas. Both of the shipyards have acquired ISO-14000 and ISO9000. In both of the shipyards, some waste management measures are taken to prevent pollution.
Production Engineering
Range: 4.5 - 4.5
Average Score: 4.5
Both sample shipyards have a well-established production engineering department covering
all aspects of steel and outfit, establishing an effective link between production and technical
departments. Both utilize a formalized engineering process for interim products and extensive use
of standards. Both shipyards have either a production control department or production engineering
center, which is independent of the production department. Under the organization, there is a
production engineering group which plays an important role as described above, including research
and development. Additionally, the production engineering function is partially integrated with the
design and engineering process.
Lofting Methods
Range: 4.0 - 4.0
Average Score: 4.0
The sample shipyards use full NC lofting for steel and outfit work including, for example,
information for jig setting, pipe bending, pipe and cable routing. Purpose-designed information
sheets are employed for all machines. No separate lofting function exists; instead, there is an
integration of loft and technical office functions. A 3-D product model is not used.
Master Planning
Range: 4.5 - 4.5
Average Score: 4.5
The sample shipyards have an integrated computer system which enables variations in
strategy to be assessed. The computer system basically allows interaction between the strategic,
tactical, and detailed level of planning and assessment of resource and workstation utilization.
However, there is some room for improvement.
Steelwork Scheduling
Range: 4.0 - 4.0
Average Score: 4.0
In the sample shipyards, detailed workstation loading is accomplished on the basis of work
analysis by using either manual or computer methods. Production schedules are coordinated to a
common demand schedule. Detail schedules are made using the computer based on the master
30
Outfit Scheduling
Range: 4.0 - 4.0
Average Score: 4.0
In the sample shipyards, detailed workstation loading is accomplished on the basis of work
analysis by using either manual or computer methods. Production schedules are coordinated to a
common demand schedule. Detail schedules are made using the computer based on the master
schedule, and are not generated from the 3-D model.
Production Control
Range: 4.0 - 4.0
Average Score: 4.0
The sample shipyards have implemented fully integrated scheduling and control systems.
Foremen are provided with all the information they require. Data is effectively retrieved from the
shop floor and consolidated into a computer-based management information system. The computer
system is not linked to financial and commercial systems.
Stores Control
Range: 4.0 - 4.0
Average Score: 4.0
All material and locations are fully coded in the sample shipyards. Stock levels, material
availability, and location are held on a computer system. Movement is directly recorded into the
computer system by stores personnel. The material system is integrated with production control and
costing systems. Stores Control is not yet integrated with a 3-D product model.
Quality Assurance
Range: 4.0 - 4.5
Average Score: 4.25
The sample shipyards use an accredited and functioning QA system. The workforce is
trained and aware of quality issues. There is full traceability of all ship components and documents
in one shipyard, and in the other shipyard, there is partial traceability of all ship components and
documents. There is a low level of re-work and full analysis/correction of problems. Both shipyards
31
32
Shipyard A
1972
7.2 mil. m2
8000
85000
57
Shipyard B
1957
3.3 mil. m2
6670
40000
37
2.0 mil.
7. Facilities
[Shipyard A]
Dock
No. 1
No. 2
500M
80M
13.4M
Length
Width
Depth
390M
80M
12.7M
Cranes
2 x 450T Goliath
3 x 30T Jib
Max. Size
DWT
500000
Dock
700000
No. 7
No. 3
No. 4
380M
65M
12.7M
640M
92M
13.4M
No. 6
260M
43M
12M
260M
65M
12M
1 x 200T Jib
2 x 150T Jib
2 x 80T Jib
2 x 450% Goliath
1 x 150% Jib
1 x 18T Jib
1000000
No. 5
400000
No. 8
---
250000
No. 9
150000
Ship Lift
Length
Width
Depth
175M
25M
11M
360M
70M
12.7M
360M
70M
12.7M
130M
20M
Cranes
2 x 30T Overhead
1 x 900T Goliath
1 x 900T Goliath
1 x 60T Jib
1 x 30T Jib
3 x 30T Jib
Max. Size
DWT
15,000 DWT
8,000 Disp.
400000
400000
33
3,000T Lifting
Capacity
[Shipyard B]
Dock
No. 1
No. 2
No. 3
Length
Width
283M
46M
390M
65M
640M
97.5M
Cranes
1 x 200T LLC
1 x 120T LLC
1 x 10T LLC
2 x 250T LLC
1 x 200T LLC
1 x 20T LLC
2 x 450T GC
1 x 30T LLC
1 x 20T TTC
330T
720T
900T
Cape Size
VLCC
ULCC
LNG Carriers
Aframax Tankers
Medium-size
Container Ships
Drill Ships
FPSO
Cruisers
Large-Size Container
Ships
VLCC &
Medium-size
Ships
Max. Lifting
Max. Size
Optimum Ships
34
Table of Acronyms
Acronym
Definition
3-D
Three-Dimensional
CNC
DNC
JIT
Just-In-Time
NC
Numerical Control
QA
Quality Assurance
TIG
35
Appendix A
JANUARY 2000
36
2.
Definition of Productivity
The term productivity as is generally used is a kind of yardsticks to be used for
quantitatively measuring the efficiency of a particular work or operation at a manufacturing
plant. In order to increase per capita production volume, it becomes crucially important for
a shipbuilding yards to reduce production costs by adopting such equipment or production
formula as will contribute to the reduction of personnel expenses and costs for materials.
And in the case of shipbuilding industry, the following values are generally correlated with
productivity:
1.
2.
Man hours (Number of work hours, including those of employees from design and
production sections).
Shipbuilding Facilities
The number of building berths or docks in Japan which are capable of
building ocean going vessels of 3,000 GT & above stands at about 93 as of
1999, of which 11 units are building docks for 100,000 GT & above. When
it comes to large-size building docks capable of building VLCCs, they are
mainly owned by major shipbuilders and part of medium to small
shipbuilders.
Most of the shipyards having these shipbuilding facilities were either newly
established or reconstructed/extended in the 1970s. In those days, they were
modern, large-size yards embracing shops for various kinds of shop-work,
such as steel cutting, welding and erection and field-work shops for
assembling large-size blocks and transportation thereof, all of which were
suited to the construction of large-size vessels. Besides, there were related
shops for main engine, outfitting, and the like, which were also equipped
with fairly modernized equipment.
After passing thorny periods known for capacity cutbacks, the numbers of
workshops and the number of enterprises declined. In the 1990s, further
improvements of facilities were carried out in respect of automation,
computerization, robotization, etc. As a result, highly sophisticated
computerization has come to be newly and widely adopted. In particular,
such areas as design and production have been modernized through
TRIBORN, CAD and CAM.
3.1.3
Productivity of Shipyards
3. 2.1 Productivity in Terms of the Volume of New Completions
(GT/person, CGT/person)
A careful review of changes in per capita volume of new
completion, which is generally used as a representative value of
productivity, discloses that in 1975 or thereabout when shipbuilding
output reached its peak, productivity surged as the number of
overtime hours worked increased due to the then heavy work load on
the part of shipyards. To be more specific, in 1975, total volume of
completions of the Japanese shipbuilding industry stood at about
17.00 million GT. In other words, per capita volume of new
completions marked 66.3 in terms of GT/ person or 30.6 in terms of
CGT/person, indicating a relatively high level of productivity.
Subsequently, however, productivity tended to fall in tandem with a
decline in the volume of new completions. In the1990s, following an
40
Study on Productivity
As regards productivity of Japanese shipbuilding industry, it is
considered that in periods like 1975 or thereabout when
shipbuilding output was amply in presence, Japanese shipyards used
to have a relatively heavy workload beyond the normal capacity of
employees; hence, the number of working hours, including overtime
hours worked increased, resulting in an increase in shipbuilding
output as well, aided by the then high productivity.
Subsequently, however, volume of shipbuilding output declined;
hence, productivity deteriorated, but in cases where measures were
simultaneously taken to reduce excess personnel and to improve
productivity through rationalization, automation, etc., per-capita
productivity advanced. Since Japan kept pursuing measures for
productivity improvement more positively than other shipbuilding
countries, it has been possible to appreciably improve productivity
throughout the 1990s in tandem with an increase in shipbuilding
output.
The question is how and in what way each shipbuilder of the
Japanese shipbuilding industry is going to deal with an issue on the
reduction of employees and to maintain its technological advantages
over its competitors. Moreover, what is even more important is
whether the industry will be able to cope with the need for further
automation by developing much more sophisticated computer
systems in order to improve shipbuilding productivity to make up for
the fallen number of employees.
4.
Industries, and Hanjin Heavy Industries. The shipbuilding share of these five
majors alone accounts for about 95 percent of the total volume of
newbuilding completions of South Korean shipbuilding industry with the
remaining 5 percent being built by other small-size shipbuilding companies.
It was mid-1970s when Hyundai Heavy Industries newly built a large-size
shipyard for the first time in South Korea, followed by Daewoo Shipbuilding
and Samsung Heavy Industries that built one each of such large-size yards
in the 1980s. Then, in the 1990s Halla Engineering followed suit. Besides,
the preceded three majors, i.e., Hyundai, Daewoo and Samsung, each carried
out a drastic expansion of their shipbuilding equipment capacity. Thus, South
Korea has thereby strengthened its international competitiveness and
positively promoted ship sales on the strength of low ship prices based on
lowered building costs, coupled with the technological power it gained from
abundant building experiences accumulated for years. As a result, South
Korea succeeded in getting newbuilding orders in large quantities. In this
way, it has come to assume a solid position with its share accounting for
about 30 percent of the worlds total volume of newbuilding completions. As
regards newbuilding facilities of shipbuilders belonging to KSA (Korea
Shipbuilders Association), in 1999, there are 40 units of berths or building
docks capable of building 6,000 DWT and above, including 13 units of
building docks for VLCCs.
In 1998, however, a series of occurrences, such as aggravation of profitability
due to low ship prices, bankruptcy of Halla Engineering, and the sell-off of
Daewoo Shipbuilding due to stagnated business conditions, triggered an issue
within South Korean shipbuilding industry concerning the fragile foundation
of business management of major shipbuilders in South Korea.
The number of employees including those of shipbuilding as well as shore
sectors of KSAs member companies increased from about 35,000 in 1975 to
about 75,700 in 1998 following the construction of newbuilding yards. Of these, the
number of shipbuilding sectors employees, though has been on the increase since
1975, tended to decline from its peak in mid-1980s to as low a level as about
38,860. Thereafter, the same began to surge again along with an increase in
the shipbuilding capacity, reaching about 53,900 in 1996. The same,
however, tended to decline again, reaching 48,530 in 1998.
It is considered that in the beginning of the 2000s, business environment
surrounding shipbuilding will become severe due to such problems as excess
shipbuilding capacity and workforce, coupled with the moves of national
economy and the won exchange rate against the U.S. dollar. Thus, the
shipbuilding industry itself will be required to undergo structural changes;
hence, volume of shipbuilding output will be correspondingly affected.
4.1.2
44
Year
GT/Person
Whole Employees
CGT/Person
Newshipbuilding
5.
1975
11.7
1980
12.3
1985
36.1
1990
64
1995
79.9
1998
95.7
42.2
60.4
81.5
Conclusion
With the coming of the 2000s, world economy and industry will be subject to drastic
changes due to such factors as information revolution and changes in population. Walls as
barriers between nations are being thrown away by irresistible moves toward globalization
across the board, irrespective of advanced or developing countries. Given such situation, it
is expected that following the recovery of Asian countries from financial and economic
crises of 1997 and subsequent economic development at a tempo much faster than originally
thought, world trade and shipping, will be given a fresh impetus, entailing an increase in the
demand for ships.
And in terms of distribution of shipbuilding shares among shipbuilding countries, a gradual
shift is being carried out from advanced to less developed shipbuilding countries in Asia,
reflecting a natural flow of the times.
As a consequence, shipbuilding productivity will be accelerated much faster and more
effectively than so far seen through modernization of shipbuilding equipment and
introduction of IT (Information Technology).
What should be borne in mind, however, is that whatever IT we may deal with, it is always
human who operates it, makes out programs, and puts data into a computer. Not only that,
it is necessary that such a person is fully aware of the fundamentals of shipbuilding and the
actual situation. This then leads us to that without advancement in the technological
standards of persons who are concerned with shipbuilding, it would be difficult to enhance
productivity of any processing or manufacturing machinery or the overall system by means
of automation or sophisticated computerization.
45
Table of Acronyms
Acronym
Definition
CGT
GT
Gross Tons
HS
IT
Information Technology
SAJ
46
Table-2 (J-2):
Table-3 (J-3):
Table-4 (J-4):
Table-5 (J-5):
Table-6 (K-1):
Table-7 (K-2)
Fig. 1:
Fig. 2:
Fig. 3:
Fig. 4:
Fig. 5:
47
(TABLE 1:J-1)
(100
Year
Completed Tonnage
(1)
(2)
x 1,000
1970
1971
1973
1975
1977
1980
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
(Estimate)
GT
10,100
14,751
16,991
11,708
6,094
9,503
8,178
5,708
4,040
5,365
6,824
7,315
7,852
8,930
8,643
9,300
10,182
9,864
10,206
12,500
GT
Number of Employee
(3)
x 1,000
CGT
5,310
16,000
7,850
5,048
6,533
2,942
3,664
4,456
4,538
4,723
4,932
5,307
5,739
6,085
6,153
7,510
9,100
Productivity
234.5
253.7
256.3
215.7
164.2
133.6
98.3
86.1
83.3
86.6
89.0
92.0
92.2
90.4
86.2
82.6
80.4
80.9
76.0
592
593
657
646
672
649
649
675
700
635
634
611
597
580
585
529
535
515
(6) = (2)/(3)
GT/Person
CGT/Person
43.1
58.1
66.3
54.3
37.1
71.1
83.2
66.3
48.5
62.0
76.7
79.5
85.2
98.8
100.3
112.6
126.6
121.9
134.3
22.6
30.6
30.7
48.9
35.3
42.3
50.1
49.3
51.2
54.6
61.6
69.5
75.7
76.1
98.8
Remarks:
GT
0.65
0.88
1.00
0.82
0.56
1.07
1.25
1.00
0.73
0.94
1.16
1.20
1.29
1.49
1.51
1.70
1.91
1.84
2.03
as '75=1.00
0.74
1.00
1.00
1.60
1.15
1.38
1.64
1.61
1.67
1.78
2.01
2.27
2.47
2.49
3.23
(TABLE 2:J-2)
Year
(1)
(2)
x 1,000GT
1965
1970
1974
1975
1977
1980
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
(Estimate)
Remarks:
5,110
9,100
14,706
13,839
6,361
5,790
7,131
7,391
3,443
3,986
5,515
6,129
6,870
7,426
8,326
8,011
8,669
9,845
9,184
Number of Employee
(3)
x 1,000CGT
(4)
Productivity
(6) = (1)/(3)
(7) = (1)/(5)
Labour Hours
(8), Index of (6)
(9),Index of (7)
(5)
x 1.000
No. of Yard
GT/Person
GT/L,Hour
as '75 =1.00
as '75 = 100
x millionH
103.4
113.0
118.4
124.9
101.2
60.9
64.4
56.3
39.3
36.8
35.8
38.0
39.9
47.9
46.0
41.6
40.4
39.5
41.4
37.9
27
28
35
35
34
34
33
33
33
39
39
39
39
39
39
39
39
39
39
49.4
80.5
124.2
110.8
62.9
95.1
110.7
131.3
87.6
108.3
154.1
161.3
172.2
155.0
181.0
192.6
214.6
249.2
221.8
0.020
0.45
0.73
1.12
1.00
0.57
0.86
1.00
1.19
0.79
0.98
1.39
1.46
1.55
1.40
1.63
1.74
1.94
2.25
2.00
0.34
0.00
0.93
1.00
0.63
0.63
0.98
1.36
0.80
0.93
1.19
1.29
1.34
1.47
1.69
1.64
1.81
2.05
2.20
252.74
0.055
0.059
0.037
0.037
0.058
0.080
0.047
0.055
0.070
0.076
0.079
0.087
0.100
0.097
0.107
0.121
0.130
269.74
234.69
170.69
157.82
121.94
92.59
72.62
71.90
78.84
80.13
86.69
85.40
83.57
82.47
81.10
81.21
70.60
(TABLE 3:J-3)
Year
Completed Tonnage
(1)
(2)
x 1,000
1970
1974
1975
1977
1980
1985
1990
1991
1992
1993
1994
1995
1996
1997
1998
GT
10,344
15,830
14,387
10,070
4,973
7,609
5,554
6,176
6,541
8,080
7,291
8,042
8,524
8,309
8,542
Number of Employee
(3)
x 1,000
CGT
(4)
Productivity
(5) = (1)/(3)
(6) = (1)/(4)
x 1.000
x 1.000
GT/Person
GT/Person
as '75=1.00
/ yards
158.60
160.55
131.82
99.8
89.6
109.1
1.00
23/51
74.69
72.76
35.41
37.93
40.61
41.94
40.23
38.32
37.10
38.34
38.23
58.01
58.04
28.73
30.49
33.00
32.26
33.71
33.07
32.42
36.11
33.96
66.6
104.6
156.8
162.8
161.1
192.7
181.2
209.9
229.8
216.7
223.4
85.7
131.1
193.3
202.6
198.2
250.5
216.3
243.2
262.9
230.1
251.5
0.79
1.20
1.77
1.86
1.82
2.30
1.98
2.23
2.41
2.11
2.31
23/46
23/44
18/38
18/38
18/38
18/38
18/38
18/38
18/38
18/38
18/36
Remarks:
(1) - Shipbuilding Association of Japan, SAJ statistics
(3) - SAJ, Shipbuilding Division, Newbuild. and Shiprepair Dept. including subcontractors in shipyard
(4) - SAJ, Newbuilding Dept. only, except Shiprepair Dept.
(TABLE 4:J-4)
Year
Completed Tonnage
(1)
(2)
x 1,000
1975
1980
1985
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
GT
10,696
2,866
4,726
3,093
3,458
3,955
4,924
3,835
4,577
4,684
4,515
4,451
5,778
Number of Employee
(3)
x 1,000
CGT
1,779
2,065
2,026
2,463
2,672
(4)
Productivity
(5) = (1)/(3)
(6) = (1)/(4)
x 1.000
x 1.000
GT/Person
GT/Person
108.95
50.86
49.83
21.76
23.49
25.65
25.87
24.16
22.85
21.95
23.32
22.72
21.97
89.20
38.35
38.59
17.52
18.75
20.74
20.06
19.89
19.27
18.96
20.22
19.85
19.08
98.2
56.4
94.8
142.1
147.2
154.2
190.3
158.7
200.3
213.4
193.6
195.9
263.0
119.9
74.7
122.5
176.5
184.4
190.7
245.5
192.8
237.5
247.0
223.3
224.2
302.8
Remarks:
(1) - SAJ statistics and JAMRI
(2) - SAJ statistics and JAMRI
(3) - SAJ, Shipbuilding Division (Newbuild. & Shiprepair Dept.including subcontractors)
(4) - SAJ, Newbuilding Dept. only.
(7) = (2)/(4)
CGT/Person
89.4
107.2
106.9
121.8
134.6
1.00
0.62
1.02
1.47
1.54
1.59
2.05
1.61
1.98
2.06
1.86
1.87
2.53
(TABLE 5:J-5)
Completed Tonnage
Year
(1)
(2)
x 1,000
1975
1980
1985
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
GT
2,156
671
786
553
697
636
920
503
403
635
652
702
1,069
Number of Employee
(3)
x 1,000
CGT
219
213
248
333
426
(4)
Productivity
(5) = (1)/(3)
(6) = (1)/(4)
x 1.000
x 1.000
GT/Person
GT/Person
18.96
9.30
9.53
3.85
4.15
4.70
4.92
3.74
3.71
2.92
2.51
2.49
2.34
15.30
7.21
7.37
3.16
3.42
3.95
4.10
3.21
3.20
2.64
2.10
2.03
2.00
113.7
72.2
82.5
143.6
168.0
135.3
187.0
134.5
108.6
217.5
259.8
281.9
456.8
140.9
93.1
106.6
175.0
203.8
161.0
224.4
156.7
125.9
240.5
310.5
345.8
534.5
Remarks:
(1) - SAJ and JAMRI statistics
(2) - SAJ and JAMRI statistics
(3) - SAJ, Shipbuilding Division (Newbuild. Dept.& Shiprepair Dept. including subcontactors)
(4) - SAJ, Newbuilding Dept. only, except Shiprepair Dept.
(7) = (2)/(4)
CGT/Person
68.2
66.6
93.9
158.6
209.9
1.00
0.66
0.76
1.24
1.45
1.14
1.59
1.11
0.89
1.71
2.20
2.45
3.79
(TABLE 6:K-1)
Year
Completed Tonnage
(1)
(2)
x 1,000
1970
1975
1980
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
(Estimate)
GT
2
410
522
2,620
3,642
2,091
3,174
3,102
3,460
3,737
4,517
4,666
4,230
6,210
7,374
8,124
7,243
10,500
Number of Employee
(3)
x 1,000
CGT
446
1,618
1,505
1,389
1,641
1,940
2,004
2,130
2,172
3,029
3,728
4,017
3,956
5,800
(4)
x 1.000
17.70
35.00
42.50
72.50
61.80
57.10
49.20
50.90
54.10
53.20
52.80
56.70
70.60
77.30
81.40
77.80
75.70
Productivity
(5) = (1)/(3)
x 1.000
GT/Person
38.86
36.64
36.25
38.13
41.00
50.17
53.89
50.14
48.53
0.1
11.7
12.3
36.1
58.9
36.6
64.5
60.9
64.0
70.2
85.5
82.3
59.9
80.3
90.6
104.4
95.7
(6) = (2)/(4)
Remarks:
(1) - Lloyd's Statistics, 100GT and above merchant ship
(2) - Before 1992 - AWES statistics; After 1993 - Lloyd's Statistic
(3) - The Korea Shipbuilding Assocation, KSA statistics,Shipbuilding Dept.
(officers, engineer, worker including subcontractors)and Land Machine Manufature Dept.
(4) - After 1990, Shipbuilding Devision only.
GT/Person
as '75 = 100
as '90 = 100
42.2
52.9
55.3
55.9
53.0
60.4
69.2
80.1
81.5
0.01
1.00
1.05
3.09
5.03
3.13
5.51
5.21
5.47
6.00
7.31
7.03
5.12
6.86
7.74
8.92
8.18
1.00
1.25
1.31
1.32
1.26
1.43
1.64
1.90
1.93
(TABLE 7:K-2)
1980
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
(Estimate)
(1)
Completed Tonnage
(2)
GT
x 1,000
x 1,000CGT
519
1,423
1,362
1,174
1,699
1,171
1,802
2,185
1,863
1,410
2,332
2,260
1,112
3,087
1,311
2,510
1,512
2,946
1,186
(3)
Number of Employee
(4)
x 1.000
x 1.000
30.20
26.80
25.60
20.80
22.70
24.30
23.10
23.70
26.20
31.70
31.80
33.40
31.40
14.50
14.90
15.50
14.50
15.80
17.90
14.80
15.70
(5) = (1)/(3)
GT/Person
47.1
50.8
45.9
81.7
51.6
74.2
94.6
78.6
53.8
73.6
71.1
92.4
79.9
Remarks:
(1) - Lloyd's Statistics, 100GT above merchant ship
(2) - Before 1992 - AWES statistics; After 1993 - Lloyd's Statistic
(3) - The Korea Shipbuilding Assocation, KSA statistics, Shipbuilding Dept.
(officers, engineer, worker including subcontractors) and Lard Machine Manufacture Division.
(4) - After 1990, Shipbuilding Devision only.
Productivity
(6) = (1)/(4)
GT/Person
150.7
125.0
91.0
160.8
143.0
172.5
169.6
187.6
(7) = (2)/(4)
70.40
73.20
102.20
75.50
COMPLETED GT.
18,000
GT/PERSON
CGT/PERSON
160.0
16,991
16,000
134.3
14,751
140.0
126.6
112.6
11,708
12,000
98.8100.3
10,100
76.7
8,178
71.1
58.1
6,000
66.3
66.3
54.3
6,094
48.9
43.1
79.5
9,300
8,930
8,643
75.7 76.1
7,315
6,824
100.0
80.0
69.5
7,852
62.0
98.8
120.0
10,182 10,206
9,864
85.2
9,50383.2
10,000
8,000
12,500
61.6
60.0
54.6
48.5
5,708
50.1 49.3 51.2
5,365
42.3
37.1
4,000
4,040
40.0
30.7
30.6
35.3
22.6
20.0
2,000
0.0
1971
1973
1975
1977
1979
1981
1983
1985
YEAR
1987
1989
1991
1993
1995
1997
1999
121.9
14,000
GT/LABOR.H
300.0
0.140
0.130
0.121
0.120
0.107
249.2
0.100
0.097
200.0
0.087
0.080
0.079
0.076
0.070
150.0
0.059
0.055
110.8
0.037
0.037
110.7
95.1
0.080
155.0
0.060
108.3
0.040
87.6
80.5
50.0 0.020
192.6
181.0
0.055
131.3
0.047
124.2
100.0
0.100
172.2
161.3
154.1
0.058
221.8
214.6
62.9
0.020
49.4
0.0
0.000
1965
1967
1969
1974
1977
1979
1981
1983
1985
YEAR
1987
1989
1991
1993
1995
1997
250.0
MAIN YARDS
7-MAJORS
300
256.3
253.7
250
234.5
NUMBER OF EMPLOYEES
215.7
200
164.2
150
133.6
118.4
113
124.9
103.4
101.2
100
98.3
108.95
86.1
60.9
64.4
86.6
36.8
35.8
89
92
56.3
39.3
50
50.86
83.3
49.83
92.2
47.9
90.4
46
86.2
82.6
80.4
80.9
41.6
40.4
39.5
41.4
37.9
76
38
39.9
21.76
23.49
25.65
25.87
24.16
22.85
21.95
23.32
22.72
21.97
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
0
1965
1970
1973
1974
1975
1977
1980
1985
1986
1987
1988
1989
YEAR
CGT/PERSON
120.0
104.4
95.7
100.0
COMPLETED TONN. PER PERSON (GT/P, CGT/P)
90.6
85.5
82.3
80.3
80.0
80.1
70.2
64.5
60.9
58.9
60.0
81.5
64.0
69.2
59.9
60.4
52.9
36.1
40.0
20.0
11.7
55.3 55.9
53.0
36.6
42.2
12.3
0.1
0.0
1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999
YEAR
Shipbulding Dept.
90.00
81.40
80.00
77.80
77.30
72.50
75.70
70.60
70.00
61.80
60.00
57.10
56.70
54.10
49.20
50.00
50.90
53.20 52.80
53.89
50.17
42.50
40.00
50.14
48.53
41.00
35.00
38.86
36.64 36.25
38.13
30.00
20.00 17.70
10.00
0.00
1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999
YEAR